My from scratch LX450 rear bumper build (1 Viewer)

Wheelingnoob · May 29, 2012

western flyer said:
Good job Jeremy! Great pics and write-up. I know how hard it its to stop and document your work. The problem solving process is evident.

This is really cool, in that I have my first welder and a couple projects now under my belt. You make this seem doable for someone like me with a bit more practice. Thanks for the hard work.

Now it will be really bomber if you add a stout hitch receiver.

BTW, every time I see your avatar pic I really think for a moment that you are Zach Galifianakis...

Thanks a lot!

In the last picture posted you can see the receiver stock I have to use on this bumper. Its just not one of the big things on my list at the moment. With only a couple hours a night to work on it I'm focus on getting the bumper structure done then all the details. The receiver will take about 30-45min to get put in, should be in the next few days.

I'm glad this is motivation for you to take on some of your projects. I learned by doing, if I cant do something I research how its been done in the past and use that as a guide.

I do have a striking reassemblence to Zach when I have a beard, maybe just a few lbs lighter. My sister in law calls me "Fat Jesus" in reference to Hangover

.

Wheelingnoob · May 29, 2012

Just ordered 2x 90lb gas struts for the swing outs from McMastercarr. I plan to use those along with stops to hold the swing outs open when needed.

akarilo · May 29, 2012

Nice work man.

western flyer · May 29, 2012

Coolness! I do see the receiver tube in that last pic (now). I will also copy some of your tricks for the expo pop-up trailer I am contemplating. Your thread has my design/creative cap spinning and now I want to build a bumper. Thanks.

Funner · May 30, 2012

looking for progress, or at least pictures of progress. Get back to work.

Wheelingnoob · May 31, 2012

Funner said:
looking for progress, or at least pictures of progress. Get back to work.

Sorry I have a life as well so have not worked on it for a couple nights.

No work done last night on the bumper but I did order this yesterday.

http://www.ddmtuning.com/Products/LED-Work-Lamp

I ordered it in a flood pattern and it will be used as a rev and work light. Very low Amp draw so I can use it for long periods with out worry of drain on the battery.

Tonight I hope to get the side wings all mocked up and ready for welding, still need to sort out the top of the sides and then the rear deck to fill the gap between the bumper and the body.

When that is all done then I will start on the swing outs, I had planed on using 1/8th 2x3 tubing but have been warned that that is to thin possibly so I guess I will need to get 3/16th, this thing is going to very heavy.

Layonnn · May 31, 2012

Wheelingnoob said:
When that is all done then I will start on the swing outs, I had planed on using 1/8th 2x3 tubing but have been warned that that is to thin possibly so I guess I will need to get 3/16th, this thing is going to very heavy.

Really liking the progress so far!
How much do you think you will be in for it in costs of steel?

And most rears are heavy as hell. My 4x4 labs rear was right around 175ish with dual swing outs (tire carrier and nothing on PS.

Wheelingnoob · May 31, 2012

Layonnn said:
Really liking the progress so far!
How much do you think you will be in for it in costs of steel?

And most rears are heavy as hell. My 4x4 labs rear was right around 175ish with dual swing outs (tire carrier and nothing on PS.

Thanks a lot.

So far in metal I am at $210 with tax (13%) this is also in Canada so everything costs more so I'm sure metal does as well. I still need to get some more metal to finish the bumper its self then the swing outs so probably another $200 total.

Overall I would like to have this all said and done around $700.

Funner · Jun 1, 2012

Wheelingnoob said:
Sorry I have a life as well so have not worked on it for a couple nights.

No work done last night on the bumper but I did order this yesterday.

http://www.ddmtuning.com/Products/LED-Work-Lamp

I ordered it in a flood pattern and it will be used as a rev and work light. Very low Amp draw so I can use it for long periods with out worry of drain on the battery.

Tonight I hope to get the side wings all mocked up and ready for welding, still need to sort out the top of the sides and then the rear deck to fill the gap between the bumper and the body.

When that is all done then I will start on the swing outs, I had planed on using 1/8th 2x3 tubing but have been warned that that is to thin possibly so I guess I will need to get 3/16th, this thing is going to very heavy.

It's definitely nice to have more light out back. I added some LED High power back up lights from a fellow mudder and they make a huge difference. I think I am going to figure out a way to run a switch from the dash to turn them on/off with out having to be in reverse. Might be a good way of getting a tailgater off my ass too.

Any chance you are going to mount the light so it is removable with maybe an extension so you can use it as a had held unit as well? Not sure about the extra wire though. Maybe a coil or just a fitting so you can remove the light and add an extension...

Wheelingnoob · Jun 1, 2012

Day 6

Got back on it last night after work. I got the material I needed for the top plate and to also finish up the boat sides and tail.

I started on the finish pice for the rear of the bumper, the frame rails are actually 4.75"" tall and I used a 2x4 piece as the main bar so that left me with a gap on the bottom. I got a length of 2" x 3/16th and cut the angles to work and blend in with the side wings.

Marked for cut

Then cut

This is the difference in the frame to bumper tube I was referring too.

I then cut the angle on the side wings to blend in together, I was very happy this all worked first time.

I then moved onto the top of the side wings and trying to come up with something I liked there. I settled on this style I like the way it works with the larger mouldings that the LX450 has.

I'm still working on the top plate that will close it in and then I need to work on the rear and making it look right when I bring it into the bumper beam.

I also was able to get my welder dialled in a bit better, I changed from my usual .030 wire to .035 and it made more of a difference in the settings needed than I though.

I'm headed up camping this weekend so that's it for this week.

:cheers:

Wheelingnoob · Jun 1, 2012

Funner said:
It's definitely nice to have more light out back. I added some LED High power back up lights from a fellow mudder and they make a huge difference. I think I am going to figure out a way to run a switch from the dash to turn them on/off with out having to be in reverse. Might be a good way of getting a tailgater off my ass too.

Any chance you are going to mount the light so it is removable with maybe an extension so you can use it as a had held unit as well? Not sure about the extra wire though. Maybe a coil or just a fitting so you can remove the light and add an extension...

Yeah I got a plan to make it adjustable in both hight and angle. I do not plan to make it removable though. I already have the 5W Cree rev light bulbs so this will be just for extra light at camp and backing up in very dark areas. Looking forward to getting it and see what I can come up with.

dagwood85 · Jul 27, 2012

been watching this, wondering if the bumper is finished? painted? finish pics installed? Come on fat Jesus, we need to see this, don't leave us hanging

Fraglerock · Jul 27, 2012

X2, love the progress thus far. Really like your design for the wings.

Wheelingnoob · Jul 28, 2012

I have got quite a bit more done, i have been taking pictures and will post them and a write up once its done. I have been slowed down the last month by starting a new job that is consuming a lot of my time and my wedding coming up in a week. Once we get back from our honeymoon in September I hope to get it finished up.

dagwood85 · Jul 28, 2012

wedding, say no more. I'm glad to hear you are still going at it. i am excited to see her all finished up. Congrats to you and the lucky lady. Hope all goes well on your big day. :cheers:

Wheelingnoob · Oct 16, 2012

Ok so I have the bumper its self done now, the wings worked out great as I had them mocked up in the last picture. The fitting welding and grinding sucked up days of work. Once I had all the grinding done I was able ot lay a thick coat of POR15 on the back side and areas with heavy wear, I also put it on all welded joints to make sure they where sealed well. I then laid a 6 coats of krylon Duo Semi gloss black.

I will post some more pictures of the process once I have access to my computer.

Over all I am very happy with the outcome, the bumper its self weighs about 170-180lbs not too bad considering its all 3/16th. The swing outs are not done yet as I needed the bumper on the truck to finish them off. The truck was in the body shop getting damage from a rear ender my Wife got into 2 days before our wedding (got an ARB winch bumper out of it though

)

Hope to get the swing outs done in the next few weeks. Looks like the Jerry can side carrier will have a ladder too since we are looking very closely at getting a ARB Sampson III RTT in the future. I will have a jerry can holder that bolts onto that I think.......still mulling this over. My issue is the trips I use the RTT will most likely also need the 15 gallons of fuel in the cans.

I will try and get the last part of the build pictures up in the next few days.

:cheers: